Lubricated non-woven fabric

ABSTRACT

A needled non-woven fabric which comprises a needled web of crimped fibers of a synthetic thermoplastic material such as a polyolefin or a polypropylene. Said web and the fibers thereof being lubricated and including a series of lengthwise extending, spaced warp threads of a material such as cotton which are relatively inextensible in comparison with the needled web of fibers. The thermoplastic fibers comprising the needled web being bonded or fused into engagement with each other on one or both exterior surfaces of the fabric. The fibers on one such surface also being bonded or fused into engagement with the warp threads. The remaining or interior fibers of the fabric being unfused and mobile or movable relative to each other. The fibers of the needled fabric being lubricated with a lubricant such as coconut oil to increase the mobility of the unfused fibers and to reduce the noise resulting from tufting of the fabric. The lubricant also prevents overheating of the tufting needles.

United States Patent 1 Parlin 1 March 6, 1973 LUBRICATED NON-WOVENFABRIC [75] Inventor: David B. Parlin, Thompsonville,

Conn.

[73] Assignee: Bigelow-Sanford, Inc., New York,

[22] Filed: Feb. 3, 1971 [21] Appl.N0.: 112,247

Related US. Application Data [62] Division of Ser. No. 713,186, March14, 1968, Pat.

[52] US. Cl. ..l61/55, 28/722, 156/148, 156/177, 156/178, 156/306,161/59,

[51] Int. Cl ..B32b 5/12, B32b 5/06 [58] Field of Search ..28/72.2;156/176, 177, 178, 156/179, 148; 161/154, 141, 142, 143, 50,

[56] References Cited UNITED STATES PATENTS 3,535,178 10/1970 Parlin eta1. ..156/l48 3,322,607 5/1967 Jung ..16l/67 3,483,601 12/1969 Smith..l6l/l54 3,154,462 10/1964 Smith ..l6l/l54 2,943,379 7/1960 Foltz..161/l41 2,908,064 10/1959 Lauterbach et al. ..16l/l54 2,910,76311/1959 Lauterbach ..l61/l54 3,060,072 10/1962 Parlin et a1. ..28/72.2

Primary Examiner-William A. Powell Assistant Examiner-James .1. BellAttorney-John F. Ryan et a1.

[57] ABSTRACT A needled non-woven fabric which comprises a needled webof crimped fibers of a synthetic thermoplastic material such as apolyolefin or a polypropylene. Said web and the fibers thereof beinglubricated and including a series of lengthwise extending, spaced warpthreads of a material such as cotton which are relatively inextensiblein comparison with the needled web of fibers.

The thermoplastic fibers comprising the needled web being bonded orfused into engagement with each other on one or both exterior surfacesof the fabric. The fibers on one such surface also being bonded or fusedinto engagement with the warp threads. The remaining or interior fibersof the fabric being unfused and mobile or movable relative to eachother.

The fibers of the needled fabric being lubricated with a lubricant suchas coconut oil to increase the mobility of the unfused fibers and toreduce the noise resulting from tufting of the fabric. The lubricantalso prevents overheating of the tufting needles.

10 Claims, 7 Drawing Figures PATENTED 61975 3,719,546 SHEET 10$ 2 Fig-5-I N VEN TOR.

DAV\D B. PARLIN PATENTEDHAR 61973 SHEET 2 BF 2 I N VEN TOR.

DAVID B; PARUN LUBRICATED NON-WOVEN FABRIC This application is adivision of copending application Ser. No. 713,186 filed Mar. 14, l968now U.S. Pat. No. 3,576,687, issued Apr. 27, l97l.

THE INVENTION The present invention relates to a needed non-wovenfabric. It relates more particularly, to a lubricated nonwoven fabric ofthe needled type which is suitable for use as the backing fabric fortufted carpet or the like.

An object of the present invention is to provide a needled-type ofnon-woven fabric comprised of thermoplastic fibers in which part of thefibers are mobile and carry a lubricant. This permits the mobile fibersto be deflected more readily by tufting needles and as a result, thereis little loss or change in the strength of the fabric when it istufted. This permits the tufting needles to be spaced more closely thanis usually the case.

The lubricant also reduces pounding and noise due to tufting operationsand it prevents the tufting needles from reaching a temperature wheredamage to the tufting yarns may result.

Another object of the present invention is to provide a non-woven fabricof the needled type in which warp threads are incorporated in and extendlengthwise of the fabric adjacent one surface thereof. Such a fabric canbe produced at less expense than when woven threads are employed.

Generally speaking, a non-woven fabric of the type to which the presentinvention relates is described and claimed in US. Pat. No. 3,394,043issued July 23, 1968 in the names of David B. Parlin and Philip B.Mitchell.

Briefly, a non-woven fabric embodying the present invention comprises aneedled sheet-like web of lubricated fibers of a high strength syntheticthermoplastic material including polyolefins, polypropylenes, polyestersand the like. The fibers are intermixed and entangled by the needlingwith portions thereof being displaced vertically relative to thethickness of the web. In addition to the fibers, warp threads of cottonor a similar material extend in spaced parallel relation to each otherin a lengthwise or warpwise directionof the web adjacent one surfacethereof.

The thermoplastic fibers on one or both exterior surfaces of the web arebonded or fused into engagement with each other with the fibers on thesurface adjacent the warp threads being fused or bonded to said threads.The remaining fibers of the fabric are not fused or bonded together andremain mobile relative to each other.

A lubricant applied to the web and the fibers thereof permits a largepercentage of the unfused or unbonded fibers to be deflected or pushedaside without being severed or broken in the passage of tufting needlesthrough the fabric. As a result, there is little change in the strengthof the fabric due to tufting.

More specifically, the needled web is formed from crimped fibers of ahigh strength synthetic thermoplastic material including polyolefins,particularly polypropylene in staple or fibrilated (split film) form.Fibers of other synthetic thermoplastic materials such as polyesters andmixtures may be employed. Where fibers of polypropylene are mixed withother fibers, the percentage of polypropylene fibers in the mixture ispreferably not less than 80 percent, but this will depend on thestrength requirements. The fibers may be in the form of a 4 /2 in.staple and may vary in size up to about 15 denier with different sizesbeing mixed. For example, a mixture containing percent six denier and 25percent three denier fibers of polypropylene may be employed.

The warp threads may be of cotton, polyester, highmodulus rayon, nylon,polypropylene or the like. The material from which the warp threads aremade and the number of warp threads per inch will depend upon the costand strength requirements. In a non-woven fabric for use as the backingfabric for tufted carpet, 9/1 cotton or l8/l polyester threads at aspacing of either threads per inch have been found to providesatisfactory strength at low cost. In a four ounce fabric, this providesan elastic limit (tensile strength before permanent elongation) of about25 pounds per inch in the length or warpwise direction of the fabric.

In lubricating the fibers, an aqueous solution con taining the lubricantmay be applied to one surface of the fabric after fusing. The lubricantsolution may be applied to the surface of the fabric by a padding orlickroll. The amount of lubricant is about 4 percent by weight of thefabric and examples of solutions which have been found to besatisfactory, are solutions containing 4 percent (by weight) of coconutoil; 3 percent (by weight) of peanut oil; 2 percent (by weight) ofsilicone; 2 f: (by weight) of coconut oil with k to V4 percent of asilicone and 2 V4 percent peanut oil with A percent of a silicone.Lubricants such as cottonseed, corn, linseed and tung oil may create afire hazard and hence, are not recommended.

As mentioned, the lubricant reduces the pounding and noise resultingfrom a tufting operation and prevents the tufting needles from reachinga temperature where damage to the tufting yarns, particularly duringstoppage of the tufting machine, may result. In addition, the lubricantresults in there being little loss in the textile strength of thenon-woven fabric after tufting. As explained, the lubricant permits themobile fibers to be more readily deflected or pushed aside by thetufting needles without being broken or severed. The fibers aredeposited by a cross-lapping operation by which a large number of thefibers extend in a widthwise direction relative to the fabric and whenthe fibers are not damaged or broken by the tufting needles, the tensilestrength in the width of the fabric can be maintained with acceptablelimits.

Under these conditions, it has been found that up to 12 stitches perinch and down to 5/64 inch gauge may be employed in tufting withoutdifficulty and with little loss in the widthwise tensile strength of thebacking fabric even though the tufting needles may be in theneighborhood of 0.156 inch in diameter and hence, overlap at 12 stitchesper inch. In the case of nonrobbing or honesty" type tubular needles,the subject non-woven fabric will withstand up to nine stitches perinch, whereas woven backing of jute and similar materials are generallyrestricted to around seven stitches per inch with such needles.

These and other features of the present invention will be better andmore clearly understood from the following description and theaccompanying drawings in which:

FIG. 1 is a perspective view diagrammatically illustrating a piece ofnon-woven fabric embodying the invention with certain portions thereofbeing broken away to illustrate details of its construction and beingdrawn to a somewhat enlarged scale;

FIG. 2 is a section view taken along the line 22 of FIG. 1 and is drawnto a larger scale than FIG. 1;

FIG. 3 is a section view taken along line 3-3 of FIG. 1 and is alsodrawn to a larger scale than FIG. 1;

FIGS. 4 and 5 are section views corresponding respectively to FIGS. 2and 3, but showing the fibers and warp threads after needling and priorto fusing of the exterior surfaces thereof;

FIG. 6 is a diagrammatic plan view of machinery positioned to carry outthe invention; and

FIG. 7 is a side elevation of the machinery of FIG. 6.

It will be understood that the drawings are of a diagrammatic nature andreference should be made to the following description for a more detailexplanation of the construction of the subject fabric.

Referring now to the drawings, FIG. 1 shows a needled non-woven fabric10 formed from synthetic thermoplastic fibers of relatively highstrength such as polypropylene fibers or the equivalent thereof. Warpthreads 11 which are relatively inextensible as compared with theneedled web of fibers extend lengthwise of the fabric in spaced relationto each other and are incorporated in the fabric adjacent its lowersurface. The warp threads may be of cotton, polyester, or other materialhaving an elastic limit equal to cotton.

As will be described, the fibers are deposited by cross-lappers whichoperate in a filling direction and the fibers are deposited in afluffed-up condition on the warp threads as the warp threads advance.When the desired thickness of the fibers has been deposited on theadvancing warp threads, the fibers together with the warp threads aresubjected to the action of one or more needle looms in which barbedneedles are forced through the deposited fibers and to a point slightlybeyond the warp threads at closely spaced intervals. The barbed needleswhich are closely spaced, engage with the fibers and displace portionsof the fibers vertically with portions of some of the fibers beingdisplaced beyond the warp threads. This results in the warp threadsbeing located immediately above and adjacent the lower surface of theweb of fibers after needling.

The needling intermixes and entangles the fibers vertically relative tothe thickness of the fabric and compacts the fibers into a sheet-likeweb having substantial tensile strength. However, due to the nature ofthe needled fabric and the properties of the fibers employed, theneedled sheet-like web may be subject to undesirable elongation orstretching, particularly in its length. The warp threads which are madeof cotton or a similar material, are less subject to such elongation orstretching and thus, increase the elastic limit of the fabric in alengthwise direction.

The warp threads 11 extend lengthwise of the fabric in spaced parallelrelation to each other and in a nonwoven backing fabric for tuftedcarpet, eight warp threads to the inch may be employed. It has beenfound that 9/1 cotton or 18/1 polyester threads spaced at eight threadsto the inch will provide adequate strength for such a backing fabric andthis spacing avoids interference with or deflection of the tuftingneedles. The

use of warp threads in this manner permits the nonwoven fabric to beproduced in wide widths, such as 9 and I2 feet, without the overlappingrequired for woven materials such as cheesecloth due to limitations asto the widths in which woven materials are produced commercially. Thus,the use of warp threads permits the non-woven fabric to be produced withgreater uniformity and at less expense as weaving of the warp threads isnot required.

As shown in the drawings, the thermoplastic fibers forming the lowersurface of the needled sheet-like web are fused, as indicated at 12,into engagement with each other and with the warp threads 11 which areadjacent such surface. The warp threads are not sized or finished as inthe case of a woven material and hence, engagement of the fused fiberswith the warp threads can be more readily achieved. Such engagementprevents slippage of the warp threads relative to the fibers of thefabric and more effectively increases the tensile strength and elasticlimit of the fabric in its lengthwise direction.

The thermoplastic fibers forming the upper exterior surface of thefabric may also be bonded or fused into engagement with each other asindicated at 13, but the interior or remaining fibers of the needledsheet-like web remain in an unfused or unbonded condition and are mobileor free to move relative to each other.

A lubricant such as coconut oil carried on the fibers of the web permitsthe unbonded or unfused fibers to be more readily deflected or pushedaside without being damaged in penetration of the fabric by the tuftingneedle. A large percentage of the fibers lie in a filling or widthwisedirection of the warp threads due to cross-lapping and thus, there islittle change in the widthwise tensile strength of the fabric as theresult of tufting.

The lubricant also decreases the pounding or noise produced by thetufting operation and it prevents the tufting needles from becomingheated to a temperature where tufting yarns, such as an acrylic yarn,may be damaged during stoppage of the tufting machine.

The procedure by which the subject non-woven fabric is produced will nowbe described. As will be seen from FIGS. 6 and 7, this is a continuousprocess and for the most part conventional equipment is employed. At theoutset, a band or series of spaced warp threads 11 are drawn from a beamor creel 20 by powered rolls 21 and are guided by suitable means such asa threaded roll in spaced relation to each other onto a slatted type ofcontinuous conveyor 22 having friction strips 23 on the surface of theslats to aid in maintaining the warp threads in spaced relation and inadvancing the warp threads with the conveyor. The drive for the conveyor22 is connected to and synchronized with the power rolls 21.

As the warp threads 11 advance on the conveyor 22, fibers are depositedon the moving band or warp threads by a pair of cross-lappers 24 whichreciprocate back and forth across the width of the band of movingthreads. Each of the cross-lappers reciprocates at a speed whichdeposits four layers of the fibers on a given area of the moving warpthreads, with the fibers being laid generally in a filling directionrelative to the warp threads.

Each of the cross-lappers 24 is supplied with fibers from a garnet orcarding machine 25 and each of the garnets is in turn supplied withfibers from a secondary pair of cross-lappers 26 to which fibers aresupplied from another set of garnets 27. Feed boxes 28 supply fibers tothe second set of garnets. Fibers are delivered to the feed boxes fromthe usual blenders and pickers (not shown).

After the desired quantity of fibers has been deposited on the movingwarp threads, the fibers and the warp threads which continue to moveenter a first needling loom 29 where the fibers and the warp threads aresubjected to the needling action of small barbed needles which arereciprocated vertically and are forced through the fibers to a pointbeyond the warp threads. In this operation, the barbed needles engagewith and displace portions of the fibers vertically, causing the layerof fibers to be compacted with fibers from different levels of the layerbeing intermixed and entangled. It also forces portions of some fibersbeyond the warp threads so that the warp threads are positioned in theneedled mass of fibers immediately above the lower surfaces thereof.

From the first needling loom, the needled fibers and the warp threadspass over a dancer roll into a second needle loom 31 where the needlingoperation is repeated. The dancer roll is counterbalanced so as to actas a take-up on the needled material as it passes from the first to thesecond needle loom and it compensates for differences in the speed atwhich the material being needled passes through the needle looms.

After the second needling, the needled web passes around a second dancerroll 32 and into a J-box 33. As the needled web is drawn from the J-box33, it passes around a third dancer or take-up roll 34 and is thenguided in a vertical path between a pair of heated rolls 35 by guiderolls 36 and 37. The heated rolls 35 exert some pressure on the needledweb and are maintained at a temperature which is sufficient to causethermoplastic fibers on exterior surfaces of the needled web to fusetogether during the time the web is in contact with the walls withoutfusing fibers on the interior of the web. The thermoplastic fibers onthe lower surface of the web are also fused into engagement with thewarp threads at this time.

The needled and fused web then passes around guide rolls 38, 39 and 40and is guided in a path which brings the lower surface of the web intocontact with the surface of a padding or lick roll 41 which is rotatablymounted in a receptacle 42 containing an aqueous solution of alubricant.

After the solution containing the lubricant is applied to the lowersurface of the moving web, the web is fed over a guide roll 43 intoanother J-box 44. As the lubricated web is withdrawn from the J-box 44,it passes over a series of guide rolls 45 and around a dancer roll 46from which it is guided by rolls 47 and 48 beneath slitting wheels 47which cut the web along its outer edges to the desired width.

The cut web then passes through an inspection area to a take-mechanism48 where the web is wound into rolls of the desired length.

It will be understood that various modifications and changes may be madein the embodiment of the invention which has been shown and describedherein without departing from the scope of the invention as defined bythe following claims.

I claim:

1. A needled non-woven fabric comprising a. a series of parallely-spacedcontinuous warp threads that are unconnected to each other;

b. a layer of non-woven crimped fibers deposited on said warp threads ina transverse filling direction to form an assembly therewith;

c. said assembly of fibers and warp threads subjected to verticalneedling to be admixedtogether to position said warp threads adjacentone exterior surface of said assembly with fibers admixed on either sideof said warp threads;

d. said fibers on at least said one surface being bonded together withthe remaining fibers being unbonded and mobile relative to each other;

e. the bonded fibers on said one surface engaging with said warpthreads; and

f. a lubricant applied to the unbonded fibers.

2. A needled non-woven fabric as defined in claim 1,

wherein:

a. the fibers of the web include fibers of polyolefin materialsincluding polypropylene; and

b. the warp threads are of cotton.

3. A needled non-woven fabric as defined in claim 1,

wherein:

a. a majority of the fibers of the web are of a high strength syntheticthermoplastic material; and

b. the thermoplastic fibers on both exterior surfaces of the web arefused into engagement with each other with the interior fibers of theweb being unfused and mobile.

4. A needled non-woven fabric as defined in claim 1,

wherein:

a. the warp threads are free of size.

5. A needled non-woven fabric as defined in claim 1,

wherein:

a. the warp threads are of a polyester.

6. A needled non-woven fabric as defined in claim 1,

wherein:

a. the lubricant is coconut oil in an amount equal to about 4 percent ofthe weight of the fabric.

7. A needled non-woven fabric as defined in claim 1,

wherein:

of a. the majority of the fibers of the needled web are of polyolefin.

8. A needled non-woven fabric as defined in claim 1,

wherein:

a. the fibers of the needled web comprise a mixture of high strengthsynthetic thermoplastic material with fibers of other materials.

9. A needled non-woven fabric as defined in claim wherein:

a. the majority of the fibers of the needled web are of a polyolefinmaterial.

10. A needled non-woven fabric as defined in claim 1, wherein:

a.'the lubricant is peanut oil in an amount equal to about 3 percent ofthe weight of the fabric.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3 71 46Dated March 7 Inventor(s) David H. Parlin It is certified that errorappears in the above-identified patent and that said Letters Patent arehereby corrected as shown below:

In the Specification:

Column 2, line 14: Replace "either" by eight-;

line 29: After "2 1/2" insert per cent Signed and sealed this 27th dayof November 1973.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. RENE D. TEGTMEYER Attesting Officer ActingCommissioner of Patents FORM PO-105O (10-69) USCOMM-DC 60376-P69 2GOVERNMENT PR mm OFFICE: 1969 o3ss-334

1. A needled non-woven fabric comprising a. a series of parallely-spacedcontinuous warp threads that are unconnected to each other; b. a layerof non-woven crimped fibers deposited on said warp threads in atransverse filling direction to form an assembly therewith; c. saidassembly of fibers and warp threads subjected to vertical needling to beadmixed together to position said warp threads adjacent one exteriorsurface of said assembly with fibers admixed on either side of said warpthreads; d. said fibers on at least said one surface being bondedtogether with the remaining fibers being unbonded and mobile relative toeach other; e. the bonded fibers on said one surface engaging with saidwarp threads; and f. a lubricant applied to the unbonded fibers.
 2. Aneedled non-woven fabric as defined in claim 1, wherein: a. the fibersof the web include fibers of polyolefin materials includingpolypropylene; and b. the warp threads are of cotton.
 3. A needlednon-woven fabric as defined in claim 1, wherein: a. a majority of thefibers of the web are of a high strength synthetic thermoplasticmaterial; and b. the thermoplastic fibers on both exterior surfaces ofthe web are fused into engagement with each other with the interiorfibers of the web being unfused and mobile.
 4. A needled non-wovenfabric as defined in claim 1, wherein: a. the warp threads are free ofsize.
 5. A needled non-woven fabric as defined in claim 1, wherein: a.the warp threads are of a polyester.
 6. A needled non-woven fabric asdefined in claim 1, wherein: a. the lubricant is coconut oil in anamount equal to about 4 percent of the weight of the fabric.
 7. Aneedled non-woven fabric as defined in claim 1, wherein: of a. themajority of the fibers of the needled web are of polyolefin.
 8. Aneedled non-woven fabric as defined in claim 1, wherein: a. the fibersof the needled web comprise a mixture of high strength syntheticthermoplastic material with fibers of other materials.
 9. A needlednon-woven fabric as defined in claim 8 wherein: a. the majority of thefibers of the needled web are of a polyolefin material.